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19-0371; Rev 4; 5/97
MAX2003A Evaluation Kit
General Description
The MAX2003A evaluation kit (EV kit) is a fast charger and conditioner for NiCd (nickel cadmium) or NiMH (nickel-metal hydride) rechargeable batteries. It is configured as a switch-mode current regulator, so power dissipation is reduced compared to linear-regulator solutions. The MAX2003A IC controls a P-channel power MOSFET switch, allowing fast-charge currents up to 2A. Fast-charge termination can be accomplished by five methods: rate-of-change of temperature, negative delta voltage, maximum voltage, maximum time, and maximum temperature. The MAX2003A EV kit is a fully assembled and tested surface-mount printed circuit board.
____________________________Features
o Complete NiCd or NiMH Fast Charger o New Pulsed Trickle-Charge Mode (MAX2003A only) o Switch-Mode Operation o Up to 2A Charge Current o Charges 2 to 12 NiCd or NiMH Cells o Discharge-Before-Charge Switch o Automatic Switchover from Fast-Charge to Pulsed Trickle/Top-Off Charge o Status LEDs o Surface-Mount Components
Evaluates: MAX2003/MAX2003A
Ordering Information
PART MAX2003AEVKIT-SO TEMP. RANGE 0C to +70C BOARD TYPE Surface Mount
Component Suppliers
SUPPLIER Alpha Thermistor AVX Central Semiconductor Coilcraft Dale-Vishay International Rectifier Motorola Nihon Sanyo Siliconix PHONE (619) 549-4660 (803) 946-0690 (516) 435-1110 (847) 639-6400 (402) 564-3131 (310) 322-3331 (602) 303-5454 (805) 867-2555 (619) 661-6835 (408) 988-8000 FAX (619) 549-4791 (803) 626-3123 (516) 435-1824 (847) 639-1469 (402) 563-6418 (310) 322-3332 (602) 994-6430 (805) 867-2698 (619) 661-1055 (408) 970-3950
_________________________Quick Start
The MAX2003A EV kit is a fully assembled and tested surface-mount board. Follow the steps below to verify board operation. Do not turn on the power supply until all connections are completed. 1) Set the number of cells in the battery pack being charged by placing the shunt across J4 pins (pins 4 and 13), as shown by the silkscreen on the board. The EV kit is shipped configured for six cells and 2A of charge current. Check that jumpers JU1, JU2, and JU3 are configured as shown in Tables 1 and 2. 2) Connect the input power source (6.5V to 28V) to the 2-pin power connector J1. The input supply must be 1V greater than the maximum battery charging voltage, and capable of providing the fast-charge current; otherwise, capacitor C13 will completely charge to V IN and terminate the charge cycle. 3) Connect the battery to the 2-pin power connector J2. Observe the polarity markings. 4) Turn on the power supply to the board and use a voltmeter to confirm the voltage across the battery and the sense resistor.
________________________________________________________________ Maxim Integrated Products
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MAX2003A Evaluation Kit Evaluates: MAX2003/MAX2003A
Component List
DESIGNATION QTY C1, C4 C2, C3 C5, C7, C8, C9, C11, C12 C6, C14 C10 C13 D1 2 2 6 DESCRIPTION 22F, 10V aluminum electrolytic capacitors Sanyo 10CV22GX 0.22F, 50V ceramic capacitors 0.1F, 50V ceramic capacitors 47F, 35V aluminum electrolytic capacitors Sanyo 35CV47GX 1000pF ceramic capacitor 1F, 25V ceramic capacitors 100mA, 30V diode Central Semiconductor CMPSH-3 Dual LEDs Digi-Key P507CT-ND or Panasonic LN2162C13 1A, 30V Schottky diode Nihon EC10QS03 or Motorola MBRS130T3 12V zener diode Central Semiconductor CMPZ5242B or Motorola MMBZ5242B 3A, 40V Schottky diodes Nihon NSQ03A04 or Motorola MBRS340T3 63.4k, 1%, 1/8W resistor 3.48k, 1%, 1/8W resistor 33.2k, 1%, 1/8W resistor 1k, 5%, 1/8W resistors J3 3 2 1 2 1 1 1 100k, 5%, 1/8W resistors J4 10k, 5%, 1/8W resistors 0.120, 1%, 1W resistor Dale WSL-2512-R120-F 200k, 1%, 1/8W resistors 18.2k, 1%, 1/8W resistor 24.9k, 1%, 1/8W resistor 28.7k, 1%, 1/8W resistor JU1, JU2, JU3 SW1 None None None 3 1 4 1 1 3-pin headers Momentary switch Digi-Key P8006/7S Shunts MAX2003A PC board MAX2003A data sheet 1 1 J1, J2 2 N1 1 P1 1 DESIGNATION QTY R16 R17 R18 R20 R23 R24 RT1 RT2 2 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION 40.2k, 1%, 1/8W resistor 49.9k, 1%, 1/8W resistor 66.5k, 1%, 1/8W resistor 100k, 1%, 1/8W resistor 243, 1%, 1/8W resistor 732, 1%, 1/8W resistor 2.21k, 1%, 1/8W resistor 1.62k, 1%, 1/8W resistor 2A, 30V dual P-FET Motorola MMDF2P03HD or Siliconix Si4953DY or International Rectifier IRF7306 5A, 30V N-FET Motorola MMSF5N03HD or Siliconix Si9410DY 100H, 2.5A inductor Coilcraft DO3340-104 MAX2003A IC Maxim MAX2003ACSE Hex inverter 74HC04 National Semiconductor MM74HC04M14A or Texas Instruments SN74HC04D Voltage regulator National Semiconductor LM317LM Thermistor Alpha Thermistor P1624 2-pin term connectors Mouser 506-2MV02 3-pin term connector Mouser 506-2MV03 16-pin header
D2
1
L1 D4 1 U1
1 1
D5
1
U2
1
D3, D6 R1 R2 R3 R4, R8, R9 R5, R6, R19 R7, R11 R22 R12, R21 R13 R14 R15
2 1 1 1 3
U3 Therm
1 1
2
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MAX2003A Evaluation Kit
_______________Detailed Description
The MAX2003A EV kit is configured as a switch-mode regulator controlling a P-channel power MOSFET, P1, as shown in Figure 1. When power is applied, the MAX2003A goes into reset mode for approximately 1.5sec, and then samples the CCMD and DCMD pins. Charge status is determined by CCMD and DCMD; refer to the MAX2003A data sheet for detailed information on the operation of these pins. For this EV kit, CCMD and DCMD are grounded so that fast-charge is initiated on power-up after the reset cycle. When the MAX2003A MOD pin (pin 14) goes high, the power switch (P1) turns on via C13 and U2. Current starts to ramp up linearly through L1, producing a voltage across the sense resistor (R22). This voltage is delivered to the SNS pin (pin 9) via filter network R4 and C10. When the sense voltage reaches 0.050VCC (250mV for VCC = 5V), MOD goes low and P1 turns off. The voltage across the inductor reverses polarity because of the collapsing magnetic field, causing catch diode D3 to be forward biased and to deliver current from L1 into the battery. The inductor current ramps down linearly until the sense voltage across R22 reaches 0.044V CC (220mV for V CC = 5V), causing MOD to go high and the cycle to repeat itself. PT1624 (10k at +25C, negative temperature coefficient) connected between J2 pin 2 (BAT-) and J3 pin 3 (THERM) is provided with this EV kit to monitor temperature. If this method is used for charge termination, make sure the thermistor is in contact with the cells. Refer to the MAX2003/MAX2003A data sheet for information on how to select values for the thermistor resistive divider (RT1, RT2) and temperature-control components. RT1 and RT2 have been selected for the Alpha Thermistor to provide a 1C/minute termination rate.
Evaluates: MAX2003/MAX2003A
Maximum Temperature Termination
The Maximum Temperature Termination method is used as a safety feature and should not be needed under normal operation of the charger. When the thermistor exceeds the maximum temperature limit of the externally set TCO pin (VTCO = 1.72V for VCC = 5V in this EV kit (+50C)) or the minimum temperature limit of the internally set low-temperature fault (VLTF = 2.0V for VCC = 5V in this EV kit (+10C)), fast-charge is terminated. In this case, the TEMP pin is driven low and the TEMP fault red LED turns on. Refer to the MAX2003A data sheet for information on how to set the temperature fault limits.
Maximum Voltage Termination
The Maximum Voltage Termination method is another safety feature of the charger. If the cell voltage measured at the BAT pin exceeds that at the MCV pin, fastcharge is terminated. This EV kit has the external resistor divider set to 1.9V (V CC = 5V). Refer to the MAX2003A data sheet for information on how to set the maximum cell voltage (MCV).
Selecting the Number of Cells
The number of battery-pack cells is selected by a voltage divider. Refer to the MAX2003A data sheet for information on how to select resistive divider values. Selection of the number of cells in this EV kit is made via J4 (pins 4 and 13). Place the shunt across J4 pins to select the desired number of cells as indicated on the board. This EV kit is shipped configured for six cells.
Maximum Timeout Termination
The Maximum Timeout Termination is another safety feature. The timeout time depends on the charge rate and is set by control signals TM1 and TM2. If the timeout is reached before any other termination method is seen, fast-charge is terminated to protect the battery. Refer to Table 4 in the MAX2003/MAX2003A data sheet for timeout programming information. Control signals TM1 and TM2 are programmed via jumpers JU2 and JU3. This EV kit is shipped configured for a 1C fastcharge rate with a 90 minute timeout and top-off charge enabled.
Negative Delta Voltage Termination
The Negative Delta Voltage Termination (-V) method measures a negative voltage change to determine termination of fast-charge. -V detection is enabled (DVEN) by placing the shunt across JU1 pins 1 & 2 (DVEN to VCC). This EV kit is shipped with DVEN enabled.
Temperature Rate Termination
The Temperature Rate Termination (T/t) method terminates fast-charge when a particular rate-of-change of temperature is exceeded. An external Alpha Thermistor
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MAX2003A Evaluation Kit Evaluates: MAX2003/MAX2003A
Discharge-Before-Charge
Initiate the discharge-before-charge function by activating switch SW1. Once the momentary switch SW1 is activated, a low on-resistance, N-channel power MOSFET turns on, providing a discharge path to the battery. Simply connect an external discharge resistor (RDIS) between J3 pins 1 & 2. The discharge process continues until the per-cell voltage drops below 1V. During the discharge phase, the CHG pin goes low (LED on) for 1.375sec and high (LED off) for 0.125sec. Fastcharging begins as soon as conditions allow. Take extra care not to overheat the battery during discharge. Observe the power rating of RDIS.
Table 1. Jumper JU1 Settings
SHUNT LOCATION JU1 across pins 1&2 JU1 across pins 2&3 DVEN PIN STATUS VCC GND CHARGER STATUS DVEN = enabled DVEN = disabled
Table 2. Jumper JU2 & JU3 Settings
SHUNT LOCATION JU2 across pins 2&3 JU3 across pins 1&2 TM1 AND TM2 PIN STATUS TM1* = GND CHARGER STATUS Fast-charge rate = C, Timeout = 90 min, Top-off charge = enabled
Charge Status
Two LED indicators show the MAX2003A's charge status. Table 3 summarizes the different charge-status conditions.
Inductor Selection
The inductor value is not critical to circuit operation. However, the greater its value the lower the output ripple current. The 100H Coilcraft DO3340-104 inductor used on the evaluation board provides low output ripple current (approximately 30% of fast-charge current) and has a 2.5A current rating. Refer to the data sheet for information on how to select inductor value. For lower current (up to 1A) and lower profile applications, use Coilcraft's DO3316-104 inductor (0.215" max height).
TM2* = VCC
* Refer to the MAX2003A data sheet for more detailed information on TM1 and TM2 control signals.
Table 3. Charge Status
CHARGE STATE Fast-Charge Charge Pending Discharge-Before-Charge Charge Complete and Top-Off Temperature Fault LED STATUS Green LED on Green LED on for 0.125sec, off for 1.375sec Green LED on for 1.375sec, off for 0.125sec Green LED on for 0.125sec, off for 0.125sec Red LED on
Using the MAX2003
The MAX2003A EV kit can also be used to evaluate the MAX2003. Besides replacing the IC, the only other modification is to change the trickle-charge resistor, (R11) to 130, 2W.
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R11 10k P1A U3 LM317LM D4 R7 10k P1B D3 D6 R12 200k 1% VBAT C13 1F C5 0.1F VCC VCC N1 Si9410 J4 12 14 74HC04 7 2, 4, 6, 8, 10, 12 9 8 6 5 4 3 2 R19 100k C12 0.1F U2 BAT1, 3, 5, 16 9, 11, 13 VCC R10 USER SELECTABLE J3-2 DISCH J3-1 BAT+ RDIS L1 100H 1 IN R23 243 1% ADJ C1 VOUT 22F 2367 10V C4 22F 10V 4 C6 47F 35V C14 47F 35V D5 12V R24 732 1%
VIN
D1 CMPSH-3
BAT+
3
3
2
3
21
JU3 R9 1k
1
21
Figure 1. MAX2003A EV Kit Schematic
BATNO. OF CELLS
C2 0.22F
GND
C3 0.22F
SW1 DISCH_COMMAND
U1 MAX2003A
1 VCC D2
GND
JU1 R8 1k
DVEN
R13 18.2k 1%
R15 28.7k 1%
R17 49.9k 1%
R20 100k 1%
JU2
R22 0.12 1% 1W
VCC C11 0.1F R2 3.48k 1% R3 33.2k 1% R4 1k R1 63.4k 1%
VCC R6 100k C7 C8 0.1F 0.1F C9 0.1F
RT1 2.21k 1%
R5 100k
CCMD 2 DCMD 3 DVEN 4 TM1 5 TM2 6 TS 7 BAT 8 VSS 15 DIS 14 MOD 13 CHG 12 TEMP 11 MCV 10 TCO 9 SNS
R14 24.9k 1%
R16 40.2k 1%
R18 66.5k 1%
R21 200k 1%
THERMISTOR TO BATTERY PACK C10 1000pF
VBATT
RT2 1.62k 1%
Evaluates: MAX2003/MAX2003A
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ALL RESISTORS ARE 1/8W AND 5%, UNLESS OTHERWISE NOTED.
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MAX2003A Evaluation Kit Evaluates: MAX2003/MAX2003A
Figure 2. MAX2003A EV Kit Component Placement Guide
Figure 3. MAX2003A EV Kit PC Board Layout--Component Side
Figure 4. MAX2003A EV Kit PC Board Layout--Solder Side
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MAX2003A Evaluation Kit
NOTES
Evaluates: MAX2003/MAX2003A
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_______________________________________________________________________________________
MAX2003A Evaluation Kit Evaluates: MAX2003/MAX2003A
NOTES
Maxim cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a Maxim product. No circuit patent licenses are implied. Maxim reserves the right to change the circuitry and specifications without notice at any time.
8 _____________________Maxim Integrated Products, 120 San Gabriel Drive, Sunnyvale, CA 94086 408-737-7600 (c) 1996 Maxim Integrated Products Printed USA is a registered trademark of Maxim Integrated Products.

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